The refractory lining of kilns is crucial for their operation and longevity.
This lining is made from materials that can withstand extreme temperatures and corrosive conditions.
Here are the primary materials used in the refractory lining of kilns:
4 Key Components Explained
Refractory Bricks and Cast Refractory Concrete
Refractory bricks and cast refractory concrete are the main materials used in the refractory lining of kilns.
These materials are chosen for their ability to endure high temperatures and resist corrosion from the materials being processed.
The refractory lining acts as an insulator, protecting the steel shell of the kiln from temperatures that can exceed 1000 °C.
The thickness of the lining typically ranges from 80 to 300 mm, ensuring a significant temperature drop between the hot and cold faces of the lining.
Working Lining and Insulating Layer
The refractory lining generally consists of two layers: the working lining and the insulating layer.
The working lining, which is in direct contact with the high-temperature process, is made of a higher density, stronger, and more conductive material.
This layer is crucial for maintaining the structural integrity and thermal conductivity of the lining.
In contrast, the insulating layer is softer, lighter, and less conductive, designed specifically to provide thermal insulation.
This layer does not need the same strength and density as the working lining, focusing instead on reducing heat transfer to the kiln's exterior.
Ceramic Fibre Backing
In situations where insulation is extremely critical, an additional layer of ceramic fibre backing may be used.
This layer is similar to fibreglass insulation but is much more compressed, providing enhanced thermal insulation properties.
Ceramic fibre backing is a thin but highly efficient layer that can further reduce heat loss and protect the kiln's steel shell.
Selection Criteria
The selection of refractory materials is influenced by several factors.
These include the type of slag produced during operation, the operating temperature, and the furnace capacity.
For instance, silica is used for acidic slags, magnesia for basic slags, and alumina for neutral slags.
Other factors that affect the choice of refractory include thermal conductivity, resistance to corrosion and thermal shock, ease of installation, and maintenance requirements.
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